Modular fenestration system

ABSTRACT

A modular fenestration system includes a collection of standardized functional units such as double hung window units, casement window units, picture window units, transom units, and the like. The functional units all share common sightlines, common glass set-back, common interfaces, common design language, and are sized according to a unique modular or incremental sizing grid. The sizing grid specifies individual window units in terms of the rough opening size in which they are designed to be installed. Individual functional units are easily combinable in a vast array of combinations to create a large number of possible composite window units. The above attributes of the functional units ensures that the composite window units are architecturally pleasing and appear as though they were custom crafted. The system also includes a collection of interior and interior trim units in various architectural styles that can be attached to installed standardized functional units via the common interfaces to match the architecture of a particular home or building. A collection of matching architectural grilles and hardware also are provided, and the trim units, grills, and hardware are all historically and period accurate to represent a wide variety of architectures both past and present. Exterior and interior trim can be built up from a limited number of standard components that can be combined in a large number of ways to create a wide variety of trim profiles.

REFERENCE TO RELATED APPLICATION

This is a continuation of co-pending U.S. patent application Ser. No.13/897,779 entitled Modular Fenestration System filed on May 20, 2013,which is a continuation of U.S. patent application Ser. No. 12/645,665entitled Modular Fenestration System filed on Dec. 23, 2009, now U.S.Pat. No. 8,464,480, which in turn claims priority to U.S. provisionalpatent application Ser. No. 61/143,472 filed on Jan. 9, 2009.

TECHNICAL FIELD

This disclosure relates generally to fenestration and more specificallyto a fenestration system that includes an array of individualstandardized window units and an array of architectural accessoriesselectively attachable to the standardized window units. Thestandardized window units can be arranged in a large number ofcombinations and mulled together to form unique multi-unit windows andselected architectural accessories can be attached to define thearchitecture of the window.

BACKGROUND

Modern materials technology has greatly expanded the choices ofarchitectural styles that manufacturers of building products are able tocreate. In particular, polymeric and composite building materials lendthemselves to new production methods such as molding and extrusiontechniques that result in a greater variety of configurations, shapes,and colors of building products. It is technically possible for such newmaterials and technologies to be used to produce building products in analmost unlimited range of architectural styles and configurations ascustom crafted items. However, custom crafted building products can beprohibitively expensive for many. Meeting demand for a variety ofarchitectural styles and combinations of architectural styles in astandardized mass produced building product line for a diverse customerbase with diverse tastes is a challenge.

The challenge has been particularly acute in the fenestration or windowand door industry. While custom crafted windows and doors can be made toorder with any desired combination of configurations, architecturalstyles, and functional features, such custom crafted products are notaffordable for the majority of homeowners. The fenestration industry hastraditionally found standardization of window and door units to be apowerful tool in simplifying production processes for mass production,improving efficiency, and producing window and door products atreasonable prices for those unable or unwilling to afford custom craftedwindows and/or doors. However, such standardized lines of windows anddoors limit severely the variety and architectural choices available toconsumers. Producing standardized mass produced window and door productsthat provide customers with a wide range of functional and architecturalstyle options has not generally been possible. A related challenge hasbeen to produce a line of standardized fenestration units adapted to bearranged and mulled together in a large number of possibleconfigurations to produce compound fenestration units that areproportionally and architecturally correct and visually pleasing.

A line of windows can comprise hundreds of individual window unitsrepresenting a wide array of available window configurations and a widearray of available sizes for each configuration. A large volume ofassociated data specifying uniquely the size and configuration of eachunit available in the line must be communicated accurately toarchitects, building designers, and homeowners to enable them to makeinformed choices from the available options. Traditionally, such windowunits have been specified by, for example, the size of the glass or bythe exterior dimensions of the window unit itself, which can result in asomewhat odd and not readily meaningful specification. Further, suchspecifications have not immediately conveyed meaningful informationregarding, for instance, the rough opening size required for the window.Instead, designers have had to calculate such requirements and hope thattheir calculations are correct. This has made selection of individualwindow units and subsequent specification of rough framing requirementscomplex and time consuming. This is particularly true for compoundwindows that are made up of a plurality individual window units mulledtogether and installed in a rough opening. In such cases, thecomplexities and potential for costly errors are multiplied.

A need therefore exists for a system of windows and doors thatsuccessfully addresses the forgoing and other needs and shortcomings ofthe prior art and it is to the provision of such a system that thepresent invention is primarily directed.

SUMMARY

The entire contents of U.S. provisional patent application Ser. No.61/143,472, to which priority is claimed above, is hereby incorporatedby reference.

Briefly described, a modular fenestration system includes a set ofstandardized mass produced functional window units such as double hungwindow units, casement window units, picture window units, transomunits, and the like. The system also includes a set of architecturalelements, including interior and exterior trim units, grilles, andhardware, all of which are historically and period accurate and thatalso can be mass produced with modern materials and techniques. Thefunctional units are each available in a wide variety of sizes for eachunit type, which results in a large array of available functional units.The standardized functional units all share common sightlines, commonglass set-back, common interfaces, and common design language. Thus, allfunctional units are visually compatible with all other functional unitsof the system and other elements of the system such as grilles and trimcan be interfaced or attached to any functional unit with the samecommon interface. Accordingly, when multiple functional units areselected and mulled together to form a large compound functional unit,the resulting compound unit is consistent across its features, visuallypleasing, mimics the look of a custom crafted window, and can be adornedwith any of a variety of architecturally accurate trim units, grilles,and hardware to achieve a desired architectural look.

The functional units are sized and specified according to a uniqueincremental sizing strategy in which individual functional window unitsare specified by the unit type and rough opening size into which theyshould be installed (e.g. DH2436 for a double hung unit for a 24 inch by36 inch rough opening). Therefore, the required rough opening size, orthe required window unit for a known rough opening, is easily andreadily determined by a designer or builder from the unit'sspecification. Further, the gap enforced between individual units mulledinto a larger compound unit is such that the required rough opening sizein a particular direction is simply the sum of the rough opening sizesof the individual functional units in that direction. Thus, determiningrequired rough opening requirements for compound units is greatlysimplified.

A tool is disclosed for aiding architects in the design, within thesystem, of compound window units for use in a particular application.The tool includes scale models of the individual functional units of thesystem and scale models of the available trim and grille units of thesystem. The model functional units can be arranged and assembled on aneasel in a wide variety of combinations resulting in a wide variety ofdifferent compound window configurations. The configuration andappearance of each combination is readily apparent and, when the desiredcombination is created and selected, the full size functional units,trim units, and the like can readily be ordered.

Thus, a modular fenestration system is now provided that addresses theproblems and greatly exceeds the possibilities of existing fenestrationsystems. These and other unique aspects, features, and advantages of thesystem disclosed herein will be better understood upon review of thedetailed description set forth below when taken in conjunction with theaccompanying drawing figures, which are briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a generic functionalfenestration unit, grille, and interior and exterior trim that embodiesprinciples of the disclosed system in a preferred form.

FIG. 2 is an exploded perspective illustrating the mulling together oftwo functional units of the system to form a compound functional unit.

FIG. 3 illustrates several possible functional unit combinations andalso illustrates common sight lines and common sizing according to thedisclosure.

FIG. 4 includes cross sectional views that illustrate common glasssetback and common sill design according to principles of the disclosedsystem.

FIG. 5 illustrates a framed-in rough opening in a building for receivinga functional unit or a compound functional unit.

FIG. 6 is a perspective partially sectioned view of three exemplaryfunctional units of the system illustrating common design language.

FIG. 7 is a perspective partially sectioned view of a double hungfunctional unit of the system illustrating common interfaces.

FIGS. 8-10 are perspective views of window units and illustrateapplication of three different architectural styles of trim to a doublehung functional unit to create three distinct architectural statements.

FIG. 11 illustrates a collection of possible architectural styles thatmight be made available in the modular fenestration system.

FIGS. 12-14 illustrate a design tool for use by architects and buildingdesigners to design compound functional units using individualfunctional units of the system.

DETAILED DESCRIPTION

The modular fenestration system will now be described in more detailwith reference to the above drawing figures, wherein like parts, whereappropriate, may be identified with like reference numerals throughoutthe figures.

Referring to FIG. 1, the modular fenestration system comprises acollection of individual functional units of different types such as,for instance, double hung units, casement units, picture window units,transom units, arched units, and the like. One such functional unit, adouble hung window unit in this case, is represented by unit 10 inFIG. 1. Each functional unit 10 of the system is standardized so thatthe functional units can be mass produced efficiently and costeffectively. Further, all functional units of the system have commonphysical features, including common sight lines, common glass setback,common interfaces, and common design language, all of which aredescribed in detail below. The same collection of functional units iscommon to and forms the basic platform of the modular fenestrationsystem of the invention. Functional units are made so that multiplefunctional units can easily be arranged and mulled together in a widearray of configurations to form a correspondingly wide array of compoundfunctional units to suit virtually any design need. Because of thecommon physical features mentioned above, a resulting compoundfunctional unit is visually consistent throughout and mimics the look ofa much more expensive custom crafted window unit.

The modular fenestration system further includes a collection ofdistinct architectural packages that may include interior trim units,represented generically by trim unit 14 in FIG. 1, exterior trim units,represented generically by trim unit 16 in FIG. 1, grille units,represented generically by grille unit 12, and hardware, representedgenerically by latch 15 in FIG. 1. Each architectural package iscarefully researched and constructed to be a historically and periodaccurate reproduction of a particular architectural style such as, forexample, Old World, Colonial, Arts and Crafts, Victorian, Modern, andothers. The architectural packages also are capable of mass production,preferably using modern materials such as wood and polymer compositesand modern techniques such as extrusion and molding. Thus, thearchitectural packages also can be fabricated efficiently and costeffectively, but nevertheless have the appearance of finely craftedcustom wooden adornments. Further, the architectural packages are allattachable to any individual or compound functional unit by attachmentmechanisms, such as clips for example, that are compatible with thecommon interfaces of the functional units, as described in more detailbelow. It will thus be seen that a very large array of windows andarchitectural styles can be created by architects and designers bymixing and matching the functional units and architectural packages ofthe modular fenestration system disclosed herein.

As used herein, the term functional unit will denote a single systemgeneric fenestration unit, such as a double hung window, a casementwindow, a sidelight, a transom, an arched unit, and the like, containingstandard and functional parts of the system. In the case of a doublehung window, for example, the functional unit may include side jambs, ahead jamb, a sill, jamb liners, balancers, nailing flanges, sashes,glazing, and weatherstrip. For a tilt sash window, the functional unitmay further include the non-visible portions of the tilt and tilt latchmechanisms. In the case of a casement or awning window, the functionalunit may include a frame, a nailing flange, a sash, weatherstrip, ahinge system, non-visible portions of an operator, and some internalparts for a locking mechanism. Visible hardware, such as latches,cranks, operator covers, and lock handles are not part of a functionalunit, but instead belong to the array of architectural packages sincethey are not generic but vary according to a selected architecturalstyle.

As mentioned, the modular fenestration system includes a set or platformof functional units of various configurations and types such as, forexample, rectangular double hung window units, rectangular picturewindow units, rectangular casement window units, arched window units,eyebrow window units, triangular window units, transom units, andsidelight units. The functional units are further adapted to allow trimunits of different architectural styles to be selected and attached,using common interfaces, on the interior and exterior sides of a home inwhich a window is installed. Thus, interior décor of the home need notbe constrained by a particular choice of exterior architectural style.Some exceptions to this rule may exist in the case, for instance, ofgrilles, which are visible both from the interior and exterior of awindow.

Common interfaces of the functional units may include a common couplingor mulling mechanism for connecting two or more functional unitstogether to form a compound functional unit, typically a largemulti-component window to be installed in a large exterior wall. In oneembodiment, shown generally in FIG. 2, a first mulling strip 25 isattached to an edge of functional unit 22, and a second mulling strip26, adapted to mate with the component 25, is attached to the facingedge of functional unit 24. The two mulling strips can then be coupledand locked together to combine the individual functional units into acompound functional unit comprising, in FIG. 2 for example, side-by-sidedouble hung windows. In an alternative embodiment, the mulling systemcan be as simple as a spacer strip made of wood, a wood polymercomposite, or other suitable material, with the functional units 22 and24 being jointed together by screws or other fasteners installed throughholes in a jamb of each functional unit, thereby coupling the functionalunits together.

Regardless of the method of mulling the functional units together, thespacing or gap between the individual units, and thus the final width(or height where one unit is mulled atop another) of the compound unitis determined by the width of each unit and the thickness of the spaceror coupling mechanism disposed therebetween. As discussed in more detailbelow, the spacer, be it a simple strip or a complex interconnectingmulling system, preferably is configured to provide gaps of a standardpredetermined width between mulled functional units. In this way, astandardized sealing system can be installed in the gaps on the exteriorside of the window to seal against rain, wind, and other intrusions.Gaps of substantially the same width also simplify the construction andinstallation of interior trim pieces that cover and conceal the gaps onthe inside of a home. In addition, gaps of common width contribute to aunity of appearance in compound functional units that mimics the look ofcustom crafted windows.

It also is preferred that individual functional units be sized in such away that the outer periphery of a compound functional unit assembledfrom multiple individual functional units defines a relativelycontinuous and smooth outline without significant discontinuities fromone individual functional unit to the next. This feature, which lends aharmonious and unified appearance to the compound unit and simplifiesinterior and exterior trim components, will hereinafter be referred toas stepless transitions between individual functional units of acompound functional unit. For example, as illustrated in the left imageof FIG. 3, stepless transitions occur when double hung functional unit32 has the same width X_(a) as transom unit 35. Thus, when the bottom oftransom unit 35 is coupled to the top of double hung unit 32 to form acompound functional unit, there are stepless transitions between theindividual functional units on both sides of the compound unit.Similarly, the middle image of FIG. 3 illustrates another possiblecompound functional unit made from an eyebrow unit 36 attached atop asidelight or door unit 33. Again, the width Xb of the sidelight unit 33and the corresponding eyebrow unit 36 is the same, thus producing acontinuous outline and stepless transitions along the peripheral edgesof the compound unit. The image on the right in FIG. 3 illustratesstepless transitions in a compound functional unit made up of a picturewindow unit 34 having an arched window unit 37 secured to its top. Bothunits have a width Xc that is substantially the same, resulting in acontinuous outline and stepless transitions.

FIG. 3 also illustrates common sight lines among functional units of thesystem, according to the invention. Specifically, to the extentpossible, the vertical edges of the glazing units G of the individualfunctional units of the system align with each other when one functionalunit is attached atop another, as illustrated at 321, 322, 331, 332,341, and 342 in FIG. 3. Similarly, the horizontal edges of glazing unitsG of individual functional units align when functional units areattached together side-by-side in a compound functional unit, asillustrated at 340, 344, and 351 in FIG. 3. The concept of common sightlines also includes the feature that corresponding lineal components offunctional units of the system are, whenever possible, the same width.For instance, the bottom rails of the sashes of all primary units(double hung, casement, picture, etc.) are the same width and the sideand top rails of the sashes have a common width, which may be differentthan the width of the bottom rail, throughout the collection. Enforcingcommon sight lines across the collection of functional units lends tothe consistency and custom crafted appearance of compound windows madeup of several individual functional units attached or mulled togetherside-by-side and/or top-to-bottom.

FIG. 4 illustrates the feature of common glass setback across allfunctional units of the modular fenestration system. Referring to FIGS.4 a and 4 b, glass setback refers to the distance S from the surface ofthe glazing unit in a functional unit to the outside edge of the frameof the unit. It will be noted that since double hung windows have glassin two different planes, they can have two glass setbacks. The leftimage in FIG. 4 is a cross section from the side of a double hung windowfunctional unit showing a glass setback for the top sash of S. S is thedistance between the outside edge 420 of the unit and the plane 421 ofthe glazing in the upper sash. Similarly, the right image in FIG. 4 is across section from the side of a casement or awning window or a pictureor fixed window functional unit showing a glass setback of S. S is thedistance between the outside edge 430 of the unit and the plane 431 ofthe glazing. According to the invention, all functional units of thesystem that are combinable into compound units have common glasssetbacks S. In other words, the glazing of each functional unit of thesystem is set back the same distance from the outside edge of the unitas the glazing in all other functional units in the collection. Withrespect to double hung functional units, it has been found thatenforcing the common glass setback of S for the glazing of the uppersash of the unit provides an architecturally consistent and visuallypleasing result when double hung units are mulled together with otherfunctional units of the system to form a compound unit. As with commonsight lines, common glass setback results in compound functional unitswith a consistency of appearance reminiscent of custom craftsmanship,even though they are assembled from individual standardized and massproduced functional units.

Each of the functional units of the system further is constructed toexhibit common design language with all other functional units. Designlanguage refers to the physical configurations, sizes, profiles, andshapes of a variety of elements of the functional units, and commondesign language means that these features are the same for allfunctional units of the collection. For example, each functional unithas side jambs and a head jamb made from lineals of the same size andsame cross-sectional profile. Each has a sash angle (the angle of thebevel of the sash lineals where the sash meets the glazing) that is thesame as the sash angle for all other functional units. Similarly, eachprimary functional unit of the system, where possible, has a tall bottomrail that is the same width as the bottom rails of other primaryfunctional units. Each primary functional unit preferably has a sillthat has the same slope and cross-sectional profile as the sills of allother primary functional units of the system, even for units where asloped sill is not functionally required. For instance, in FIG. 4, thedouble hung functional unit on the left has a sill s with a slope sa andthe fixed or casement unit on the right has a sill s with the same slopesa.

Referring in more detail to FIG. 6, three functional units of a modularfenestration system according to the invention are illustrated, apicture window unit, a double hung window unit, and a casement windowunit. The system obviously will comprise a number of other types offunctional units, but these three are shown to illustrate better thecommon design language incorporated into the functional units. Wheneverpractical, the functional units of the system have jamb profiles 610,sash angles 611, tall bottom rails 612, sloped sills 613, and sillprofiles that are the same. There may be exceptions such as, forinstance, transom units and other specialty or secondary units, whichlikely do not include a sloped sill for architectural and functionalreasons. This common design language contributes further the consistent,pleasing, and custom crafted look of compound fenestration units formedfrom combined individual functional units of the system. Significantly,it also enhances the ability to mass produce the functional unitsefficiently and economically because so many of the lineal sizes andprofiles are common to all functional units of the system.

The functional units of the system are further configured with commoninterfaces, meaning that the various elements of the system that meet orjoin or are attached to other elements are secured in the same way usingthe same structures for all of the functional units of the system. Forinstance, the groove or other structure formed in the outside and insideedges of the jambs for receiving the attachment mechanism of trim unitsis common throughout the collection of functional units. Similarly, theattachment mechanism by which grille units are attached to sashes is thecommon to all functional units. And, as mentioned above, the mullingsystem by which functional units are joined together into compound unitsis common to all of the functional units of the system. FIG. 7exemplifies common interfaces for a double hung functional unit of thesystem. Interfaces include, for instance, an exterior trim interface 710designed to accept and secure a selected exterior trim unit of thesystem. Thus, an exterior trim unit of any architectural style can beattached to any individual functional unit of the system and to anycompound functional unit made up of combined individual units. Ofcourse, the attachment mechanisms of all of the exterior trim units ofthe system also are the same and designed to secure the trim units tothe exterior trim interface 710 of the functional units.

Other common interfaces include the mulling interface 711 by whichindividual functional units are mulled together, the extension jambinterface 712 to which interior extensions or other trim is attached tothe frame of the unit, and the grille interface 713 where the ends ofthe grille components are attached to the sash frames. Thus, all of thefunctional units of the collection are mulled together the same way withthe same mulling interface, extension jambs attach to all of thefunctional units of the collection in the same way with the sameinterface, exterior and interior trim units of the system attach to thefunctional units and compound functional units in the same way, andgrilles attach to the sash frames of all units in the same way. Commoninterfaces ensure that the functional units of the system can beassembled in a wide range of combinations to form a correspondingly widerange of compound units, since the units are all attached together withthe same mulling system. Further, common interfaces insure that any ofthe architectural elements of the system, such as exterior trim unitsand grille units, can be selected and attached to any of the individualfunctional units of the system and to any compound functional unit thata designer might form from individual units. It can thus be seen that avery large array of possible combinations of elements of the system isavailable to an architect or designer without concern for whether eachselected element is compatible with all of the other selected elements.

Another feature of the modular fenestration system is that thefunctional units of the system are dimensioned according to a universalsize grid that is based on a common increment such as, for example, a 4inch increment. Furthermore, as detailed below, the sizing refers not tothe physical dimensions of the unit itself, but to the required size ofthe rough framed-in opening in which the unit fits. This means that agiven functional unit type of the system can be ordered for roughopening dimensions (width and height) that vary in 4 inch increments andthat virtually all functional units of the system are available for thesame combinations of rough opening dimensions. For example, a doublehung functional unit of the system may, for purposes of illustrationonly, be available for rough openings having widths of 20, 24, 28, 32,36, or 40 inches and heights of 36, 40, 44, 48, 52, or 56 inches. Atransom unit that may be selected to be mulled atop a double hung unitalso is available for rough openings of the same set of incrementalwidths (20, 24, 28, 32, 36, or 40 inches). In this way, a compoundfunctional unit made from a transom unit for a 30 inch wide openingattached atop a double hung unit for a 30 inch wide opening will exhibitstepless transitions, common sight lines, and the other advantageousfeatures of the system of this invention.

It will be apparent that this incremental sizing Strategy for functionalunits will naturally result in a very large number of width and heightcombinations in which functional units are available to designers andbuilders. The system of this invention includes a unique strategy forspecifying all of the unit types in all of the available sizes that islogical, meaningful, and conveys useful information immediately todesigners, builders, and homeowners. More specifically, each functionalunit is specified, selected, and ordered by a designation that embodiesthe type of unit and the rough opening in which it should be installed.For example, a double hung functional unit may be specified as a DH3664unit, meaning that it is a double hung functional unit sized to beinstalled in a rough opening that is 36 inches wide by 64 inches high.Thus, all information necessary to order a needed functional unit isimmediately conveyed by the designations of the functional units. It isthus a simple matter for a designer or builder to select and orderfunctional units for a particular rough opening size, or to determinethe needed rough opening size for a selected functional unit.

This specification strategy also applies to functional units that arenot rectangular (e.g. an arched window unit, triangular window unit,eyebrow window unit, etc.). For example, an arched window unit may bedesignated as an AR7224 unit, meaning that it is an arched unit for arough opening of 72 inches wide by 24 inches tall. Additional structuralmembers may be secured within the rectangular rough opening inappropriate places to aid in attachment of the non-rectangular unit tothe structure; however, the size of the needed rough opening is stillthe basic designation of the arched unit. Further, the AR7224 isimmediately recognizable as the appropriate arched unit to be mulledatop a DH7280 or two side-by-side DH3680 units, for example. It can beseen that ordering a set of functional units that will match when mulledtogether into a larger composite functional unit becomes simple andstraight forward for designers and builders. This is unique to thefenestration industry.

The actual peripheral dimensions of a functional unit, which are smallerthan the dimensions of the required rough opening, are not immediatelygermane to home designers and architects and thus are not part of thespecification strategy of this invention. However, for the manufacturerof the functional units, each unit's actual dimensions can readily becalculated from the width (W) and height (H) of the rough openingspecification by subtracting gap widths, which also are standard for thesystem, from each of W and H. For example, the gap width used in such acalculation may be denoted by g_(w), for the horizontal gap, and g_(v)for the vertical gap. Gaps g_(w) and g_(v) are the horizontal andvertical distances between the edges of the rough opening and theclosest points of a functional unit configured to be installed in therough opening. Hence, the maximum horizontal dimension of the functionalunit is X=W−2g_(w), and the maximum vertical dimension of the functionalunit is Y=H−2g_(v). While in principle g_(w) and g_(v) can be different,it is convenient to let g_(w)=g_(v)=g_(p), wherein g_(p) is a standardgap width between the periphery of a functional unit and the roughopening, and is constant for the system. It may be assumed that the unitis centered in the rough opening, so g_(p) is the same for all sides ofthe unit. Thus, for example, if g_(w)=g_(v)=g_(p)=0.75 inch, then theactual width X of a functional unit for a 24 inch wide rough opening is24−2(0.75)=22.5 inches. Likewise, the actual height Y for a 48 inch highrough opening is 48−2(0.75)=46.5 inches.

When functional units are coupled or mulled together to form a compoundfunctional unit, gaps exist between the coupled together units. Thedesign of compound units and the rough openings needed to receive themis greatly simplified if a standard mulling gap, g_(m), is created bythe mulling system. Preferably, the mulling system for joiningindividual units to form compound units is configured to provide aconstant gap width g_(m) for all mulled gaps, both vertical andhorizontal. This assures common sight lines and stepless transitionsbetween units, as discussed above.

Judicious selection of g_(m) and g_(p) makes easy the determination ofrough opening dimensions required for any compound functional unit madeup of multiple individual functional units. More specifically, therequired dimensions of the rough opening for a compound unit depend uponthe number of individual units, u, that are combined in the horizontaldirection, and the number of individual units, v, that are combined inthe vertical direction. When u units are combined in the horizontaldirection, the number of mulled gaps between these units is u−1.Similarly, the number of mulled gaps in the vertical direction is v−1.With the width of each mulled gap being g_(m), the required horizontaland vertical rough opening dimensions for the compound unit are:

W=X ₁ +X ₂ + . . . X _(u)+2g _(w)+(u−1)g _(m)

H=Y ₁ +Y ₂ + . . . Y _(v)+2g _(v)+(v−1)g _(m)

These equations can be further simplified by letting 2g_(w)=2g_(v)=g_(m)or in other words letting the mulled gaps be the same width as the sumof the peripheral gaps in the vertical and horizontal directions. Withthese simplifications, the above equations for the dimensions of therequired rough opening for a compound functional unit may be presentedas follows:

w=X ₁ +X ₂ + . . . +X _(u) +u(g _(m))

V=Y ₁ +Y ₂ + . . . +Y _(v) +v(g _(m))

But, X (the actual width of an individual functionalunit)=W−2g_(w)=W−g_(m), where W is the rough opening width required forthe unit. Similarly, Y (the actual height of an individual functionalunit)=V−2g_(v)=V−g_(m), where V is the rough opening height required forthe unit. Substituting in the forgoing equations, we obtain:

$\begin{matrix}{W = {\left( {W_{1} - g_{m}} \right) + \left( {W_{2} - g_{m}} \right) + \ldots + \left( {W_{u} - g_{m}} \right) + {u\left( g_{m} \right)}}} \\{= {W_{1} + W_{2} + \ldots + W_{u} - {u\left( g_{m} \right)} + {u\left( g_{m} \right)}}} \\{= {W_{1} + W_{2} + \ldots + W_{u}}}\end{matrix}$ and $\begin{matrix}{V = {\left( {V_{1} - g_{m}} \right) + \left( {V_{2} - g_{m}} \right) + \ldots + \left( {V_{v} - g_{m}} \right) + {v\left( g_{m} \right)}}} \\{= {V_{1} + V_{2} + \ldots + V_{v} - {v\left( g_{m} \right)} + {v\left( g_{m} \right)}}} \\{= {V_{1} + V_{2} + \ldots + V_{v}}}\end{matrix}$

It thus can be seen that with the dimensioning and designation strategyof the present invention, the rough opening dimensions W and V requiredto receive a compound functional unit made of individual mulled togetherfunctional units is simply the sum of the rough opening requirements ofeach individual unit joined in the horizontal direction and the sum ofthe rough opening requirements of each individual unit joined in thevertical direction respectively. For example, three DH2448 units mulledside-by-side require a rough opening 72 inches wide (24+24+24) by 48inches high. Similarly, three DH2448 units side-by-side each having aTR2412 mulled atop it requires a rough opening 72 inches wide by 60inches (48+12). Thus, with the dimensioning and specification system ofthis invention, determining the required rough opening size for acompound functional unit is a simple matter of adding together thehorizontal part of the specification for all units mulled in in thehorizontal direction and adding together the vertical part of thespecification for all units mulled in the vertical direction. It hasbeen found that a convenient value for the mulled gaps (g_(m)) is 0.75inches, meaning that the peripheral gaps (g_(p)) are 0.375 inches. 0.5inches has also been found suitable in some situations for the width ofthe mulled gaps with 0.25 being the width of the peripheral gap.

For architects and building designers, this designation system and itssimplicity render the task of designing window openings for a home, bothfor individual and compound units, significantly less arduous than inthe past. Assuming that x=y=4 inches, the designer of a building canreadily determine, by simple calculation, alternative windowdesignations of units that might be mulled into a compound unit suitablefor the design of the home. For example, assume that an architect wishesto create a compound window unit with three side-by-side DH3248 units,each of which has a TR3216 mulled to its top. The rough opening sizeneeded to accommodate such a compound unit is simply 96 inches wide(three times 32) by 64 inches high (48 plus 16). Alternatively, a roughopening can be specified with dimensions that are multiples of 4 (or 2or another selected increment), and functional units from the systemthat, when mulled together, fit within the rough opening can easily bedetermined by their specifications. For instance, if a home has a roughopening 32 inches wide by 64 inches tall and a double hung window isdesired for that opening, the designer or builder need only order aDH3264 functional unit. Similarly, a rough opening 64 inches wide by 64inches high can accept two side-by-side DH3264 units.

FIG. 5 is a simplified illustration of a portion of a framed-in buildingstructure, in this case a house, illustrating what is meant by the term“rough opening” used herein. The house 1 is framed with a rough opening10 formed by vertical studs 2 and 4 and horizontal studs 6 and 8. Therough opening 10 has an inside perimeter 14 with a width W, the distancebetween the vertical studs, and a height H, the distance between thehorizontal studs. Other framing configurations also are used dependingon factors such as the size of the opening, required structural support,and the configuration of the wall. Regardless of the configuration, thebasic opening has an inside width W and an inside height H, which formthe basis of the functional unit specification system discussed above.

The modular fenestration system further includes a collection ofarchitecturally and period accurate exterior trim, grille, and hardwareunits that can be attached to an individual functional unit, or to acomposite unit made of several individual functional units, to achieve adesired architectural motif appropriate to the overall architecture of ahome. FIGS. 8-10 show, for example, a double hung functional unitincorporating the above described attributes, with architecturallydistinct trim units, grilles, and hardware of the system selected andattached to provide distinctly different impressions. FIG. 8 illustratesthe impression created by selecting an exterior trim unit, a grilleunit, and hardware exhibiting a Shingle architectural style. FIG. 9illustrates the impression created with the same double hung functionalunit by selecting and attaching an architectural trim unit exhibiting aGeorgian Federal architectural style. And FIG. 10 illustrates theimpression created by selecting trim, grille, and hardware units havinga Colonial architectural style.

As can be seen from these figures, the identical functional unitcombined with different architectural trims, grilles, and hardware ofthe system creates windows that have very different looks and feels andthat make distinct architectural impressions. The system of theinvention contemplates an available selection of trim (both exterior andinterior), grille, and hardware units that is robust and includes manyhistorical and period accurate architectures that may reasonably bedesired. FIG. 11, for instance, illustrates a collection of exteriortrim packages of varying architectural styles that might be availablefor selection by architects and designers within the system of thepresent invention. Of course, the invention is not limited to aparticular architectural style or group of styles, or indeed tohistorical architectural styles. The architectural styles illustrated inFIGS. 8-11 are thus meant to be exemplary only and represent onepossible selection of architectural styles that might be provided fortrim, grille, and hardware within the system of the invention.

FIGS. 12 through 14 illustrate a design tool that is part of the modularfenestration system of the present invention to assist architects anddesigners in designing composite fenestration units by combiningfunctional units of the system. The tool comprises small scale models ofthe functional units available in the system and an easel on which thefunctional unit models can be arranged in a wide variety of combinationsto form models of composite functional units possible within the system.In FIG. 12, various model functional units comprising picture windowunits, double hung window units, arched window units, triangular windowunits, eyebrow units, and the like are shown in the foreground and theeasel is shown in the background. Arranged on the easel are severalmodel functional units forming two different composite window units. Tothe left on the easel are two side-by-side double hung units, a transomunit over each double hung unit, and a trapezoidal unit over each of thetransoms to form a gable appearance at the top of the composite windowunit. On the right are a single picture window unit, a single transomunit atop the picture window unit, and a single gable unit atop thetransom, all forming a composite window unit having a distinctlydifferent look and architecture than the composite unit on the left.Obviously, a vast array of composite units can be designed with thistool by combining the model functional units in their many possiblecombinations on the easel and comparing the resulting architecturalimpressions until the desired look is achieved. It should be noted,however, that some possible combinations are not visually pleasing andothers are not functionally practical, so the number of viable possiblecombinations are more limited. It has been found that the design toolaccording to the invention makes designing and evaluating compound unitssubstantially easier and produces more pleasing results than in thepast, all made possible by the various components and elements of thesystem discussed in detail herein.

FIG. 13 is an enlarged view of some of the model functional units of thedesign tool, which represent actual functional units of a modularfenestration system according to the invention. The model functionalunits are accurate scale representations of the actual functional unitsso that the tool can be used to create realistic miniatures of actualcomposite window units. FIG. 14 illustrates another example of thecombination of functional units of the system to form composite windowunits, using the tool of the invention. The illustrated composite unithere comprises two picture window units side-by-side, sidelight units toeach side of the picture window units, an arched transom unit overlyingthe two picture window units, and trapezoidal transom units overlyingthe sidelight units. Such a combination might be assembled as, forexample, a large arch-top picture window in a living room, bedroom, orother room.

The invention has been described in terms of preferred embodiments andmethodologies considered by the inventors to represent the best mode ofcarrying out the invention. However, the embodiments presented are butexamples and a wide variety of additions, deletions, and modificationsmight be made to the illustrated embodiments by skilled artisans withoutdeparting from the spirit and scope of the invention as set forth in theclaims.

What is claimed is:
 1. A modular fenestration system comprising: acollection of individual functional window units including a pluralityof functional window units having different configurations with thefunctional window units of at least some of the different configurationshaving a plurality of different sizes, the individual functional windowunits each comprising a frame having a frame perimeter; a common mullingsystem comprising a coupling mechanism configured to establish apredetermined common spacing between one functional window unit of thecollection and another functional window unit of the collection attachedby the coupling mechanism; the functional window units of the collectionbeing configured such that, when combined to form a compound functionalunit, the resulting compound functional unit exhibits a predeterminedset of common physical features regardless of which functional windowunits of the collection are selected to form the compound functionalunit; a plurality of architecturally distinct exterior trim unitsconfigured to be selectively attached at least to some of the individualfunctional window units and to compound functional units formedtherefrom; a common attachment mechanism for attaching exterior trimunits to the functional window units and to compound functional unitsformed therefrom; a plurality of architecturally distinct grille unitseach configured to be secured to at least some of the individualfunctional window units; a common attachment mechanism for attachingselected grill units of the plurality of grill units to functionalwindow units; and a plurality of architecturally distinct hardware unitsconfigured to be selectively secured to at least some of the individualfunctional window units.
 2. A modular fenestration system as claimed inclaim 1 and wherein the common physical features comprise common sightlines.
 3. A modular fenestration system as claimed in claim 2 andwherein the common physical features comprise common glass setback.
 4. Amodular fenestration system as claimed in claim 3 and wherein theindividual functional units comprise a double hung window unit with anupper sash and a lower sash and wherein the glass setback of the uppersash is common to other individual functional units of the collection ofindividual functional window units.
 5. A modular fenestration system asclaimed in claim 3 and wherein the common physical features comprisecommon design language.
 6. A modular fenestration system as claimed inclaim 5 and wherein the common design language includes common jambprofiles.
 7. A modular fenestration system as claimed in claim 6 andwherein the common design language includes common sill profiles andcommon sill slope.
 8. A modular fenestration system as claimed in claim7 and wherein the common design language includes common sash linealprofiles and common sash angles.
 9. A modular fenestration system asclaimed in claim 1 and wherein the common physical features comprisecommon sight lines, common glass setback, common design language, andcommon interfaces.
 10. A modular fenestration system as claimed in claim1 and wherein the individual functional window units are sized to fitroughed-in openings that vary by a preselected increment in width and apreselected increment in height.
 11. A modular fenestration system asclaimed in claim 10 and wherein the preselected increment in width is 4inches.
 12. A modular fenestration system as claimed in claim 10 andwherein the preselected increment in height is 4 inches.
 13. A modularfenestration system as claimed in claim 10 and wherein each individualfunctional window unit is specified for installation in a building bythe size of the roughed-in opening of the building in which it is sizedto fit.
 14. A modular fenestration system as claimed in claim 13 andwherein each individual functional window unit is further specified byits configuration.
 15. A modular fenestration system as claimed in claim14 and wherein the coupling mechanism is further configured to define amull gap of a predetermined width between mulled together functionalwindow units.
 16. A modular fenestration system as claimed in claim 15and wherein the mull gap is the same in the vertical direction as is themull gap in the horizontal direction.
 17. A modular fenestration systemas claimed in claim 16 and wherein the mull gap and the dimensions ofthe functional units are selected so that a rough opening's dimensionsneeded to accommodate a compound functional unit is the sum of therequired rough opening widths for each individual functional unitcombined in the horizontal direction and the sum of the required roughopening heights for each individual functional unit combined in thevertical direction.
 18. A modular fenestration system as claimed inclaim 17 and wherein the mull gap is 0.75 inches.
 19. A modularfenestration system as claimed in claim 1 wherein the frame perimeterhas a groove formed therein and wherein the common mulling systemcomprises a first mulling member configured to be attached to the frameperimeter of one functional window unit with part of the first mullingmember extending into the groove thereof and a second mulling memberconfigured to be attached to the frame perimeter of another functionalwindow unit of the collection with part of the second mulling memberextending into the groove thereof, the first and second mulling membersbeing configured to couple and lock together to combine functionalwindow units of the collection into compound functional window units.20. A modular fenestration system as claimed in claim 1 wherein thecoupling mechanism is configured to attach functional window unitstogether to form compound fenestration units prior to installation ofthe compound fenestration units in a roughed-in opening.
 21. A modularwindow system comprising a collection of individual functional windowunits that includes functional window units of different configurationswith each configuration comprising functional window units of differentsizes, each respective configuration of functional window units ofdifferent configurations having at least one physical attribute that iscommon to the functional window units of other configurations of thefunctional window units of different configurations, each of thefunctional window units of the collection being sized to fit within oneof a plurality of roughed-in opening sizes wherein the plurality ofroughed-in opening sizes vary by a predetermined increment, the size ofeach functional window unit being different than the correspondingroughed-in opening size and the functional window unit being specifiedby the roughed-in opening size in which it fits, and a collection ofarchitectural trim packages, each of the collection of architecturaltrim packages being selectively attachable to a corresponding functionalwindow unit and being of a distinct architectural style that is periodcorrect.
 22. The modular window system of claim 21 further comprising acommon mulling system comprising a coupling mechanism configured toestablish a predetermined common spacing between one functional windowunit and another functional window unit attached thereto by the couplingmechanism, the functional window units, when attached, forming at leastpart of a compound functional window unit.
 23. The modular window systemof claim 22 wherein the collection of architectural trim packagescomprises architectural trim packages sized and configured to beselectively attached to compound functional window units formed ofindividual functional window units attached together with the couplingmechanism.